The document summarizes a presentation given at a RESNET conference on modular and manufactured housing. It discusses the challenges of achieving Energy Star certification for modular homes, including a lack of coordination between builders, manufacturers, and HERS raters. It provides examples of common issues found during inspections such as improper insulation installation and air sealing defects. The presentation concludes by emphasizing the need for continued education and training of all stakeholders to fully integrate green building practices.
1. 3/10/2009
Factory Built Housing Center
Pennsylvania College of Technology
RESNET Conference
February 18, 2009
Larry Armanda & Rick Terry
Who are we?
FBHC Projects and Energy Star Program
What is a modular?
mod lar?
Modular vs. Manufactured
Modular vs. Site Built
The Modular Process
Challenges to Energy Star with Modulars
What we found and what is happening now
Examples from the Plants
A Case Study from the Site
Challenges carry over to Green
Conclusion and Questions
1
2. 3/10/2009
Established in 2003
Part of Pennsylvania College of
Technology s
Technology’s PHRC
Grew out of the success of the
Modular Housing Training
Institute (MHTI) at the College
Featured a 2 Day Course
developed with industry and PA
DCED to address industry
recommended practices
regarding site management of
modular projects
Consult with plants to implement EPA process
Bring in HERS rater to assess and certify some
units as FBHC projects
i j
Become Energy Star Partner in 2008
Sign letter of agreement with RESNET to train
modular manufacturer QA/QC personnel as Field
Inspector Raters and seek national certification
Conduct Green Advantage Training for modular
industry as part of Commonwealth of PA
initiative (2 sessions)
Hold NAHB Green Professional certification
courses for modular industry; also PA initiative
2
3. 3/10/2009
Built to same IRC codes as traditional site
construction
Some States my have some specific code exceptions
for modulars; i.e. stair geometry, third party
inspections and approvals, liability of on site code
officials
Challenges on site include proper building science
applications, subcontractors and knowledgeable
builders
Set
S t crew, builder, & subcontractor di t b
b ild b t t disturbance of th f the
thermal envelope and work completed in plant
Dealing with Cape Cod and 2 Story designs (i.e.
separate ceiling and floor systems)
Manufactured or HUD code homes are built to a
different federal code
Structures include integrated metal frames with,
hitches, wheels and axles (Often removed on site)
h h h l d l ( f d )
Have separate programs and options for Energy Star
Certified Homes
May be placed on permanent foundation or moved
from site to site
Much confusion in public eye and even within
stakeholders of industry
Some traditionally manufactured housing plants
now building some modular “qualified” products
based on their HUD products adding additional
confusion
3
5. 3/10/2009
Traditional Site Built
Modular Production
Modular Production Traditional Site Built
5
6. 3/10/2009
Modular Housing
Represents Nearly
22% of All Housing 5
Starts in the 1
Northeast!
4
3
PA has the most 7
modular manufacturers
i th country with 39
in the t ith
plants!
39
Factory
Customer Builder
Sales
Estimating Engineering Production
Delivery & Builder Customer
Set Finish Occupies
6
7. 3/10/2009
• Customer decides to build a new home and starts process with
builder
• Customer looks at building a certified Energy Star home because
Customer they saw a program about it on “DIY Network”
•Customer comes to builder and decides to move forward with design and
estimate; asks builder about Energy Star and receives a blank stare;
builder tells customer he’ll have to get back to him on that
•Builder contacts plant and starts process for plans and estimate; forgets
about Energy Star and/or thinks it already is Energy Star because
everything has ES Label on it
Builder •Finally mentions to the modular sales person that the customer is
interested in Energy Star; sales person gives blank stare and tells builder
that he’d have to get back to him
•Factory sales person knows a little about Energy Star, but hasn’t
gone beyond knowledge of building products labeled Energy Star;
figures that he’ll take care of it once goes to production
•Asks estimating and engineering what Energy Star certification
Factory Sales means; receives blank stare
•Confers with engineering on Energy Star requirements; figures in
added material costs for Energy Star labeled bath vent, windows and
doors; appliances and HVAC “by Others”
•Work with purchasing to gather material costs and estimates project
Estimating with ES labeled materials
7
8. 3/10/2009
•Confers with 3rd Party on ES requirements; then try to find out
information from ES website; then tries to figure which ES Partnership
Agreement to fill out; then try to find out what a HERS Rater is; then
tries to find a HERS Rater
•Hands over ES certification project to QC after trying to pass it back to
Engineering sales without any luck; eventually find out the various climate zones
and guidelines for ES based on their region
•Production tries to figure out what the ES standards mean; analyzes
potential changes to production system; views it as another
management scheme to slow down the line and take away their
production bonuses!
•Finally caves in and agrees to put QC in charge of coordinating and
monitoring ES during production
g gp
Production
P d i •Find out the requirement of a TBC and cringe at the thought of yet
another inspector invading their line
•Transportation gets the house to the site as ordered; set crew begins their
“art” of assembly
•Crew already thinking about the 8 box set they have to get to tonight at
another site 200 miles away; hoping for their first 2-day weekend in 6
months if they get them all done!
•Dang! They are just handed the ES checklist the builder prepared that
Delivery - Set
y details all of the extra air sealing and insulation they need to complete
before closing up the units. Set crew foreman and builder argue about
units
scope of work and additional ES requirements; looks like another short
weekend!
• Finally locates a HERS rater and ask them to do a performance
test for certification on the site and schedules date with builder
• Project manager questions Rater why he has to charge the
manufacturer for plan review, TBC, and testing? Can’t his guys
Can t
Manufacturer just do it and check off 5 items and let the builder take care of
the rest?
8
9. 3/10/2009
•HERS Rater is contacted by the manufacturer the week the house is going
online to certify the project as meeting Energy Star standards
•Rater conscientiously explains the 3 Step Process of certification and asks for
the plans to do a plan review to make sure the house meets standards before
production
•Schedules date to complete the Thermal Bypass Checklist when the house is
on the line; gets an email the day before TBC i
h li il h d b f inspection that the unit will not
i h h i ill
be ready – postpone 1 day; receive email next day – not ready – postpone
another day; no emails the next day so Rater travels 100 miles to plant to
find only one unit out of four in position to be inspected; wait for rest of the
day as 2 more units move down line; 9 hour TBC and still not done!
•Asks for appointment for next day to finish TBC at plant, but plant shuts
HERS Rater down for hunting season and Thanksgiving break for a week so reschedule
for re-visit in 10 days when production resumes.
•Rater returns for final TBC inspection 10 days later only to pass units pulling
out of facility on their way to jobsite; plant forgot to tell Rater that a crew
came in to finish the home during the break so it could be delivered before
Christmas!
•Rater, discouraged and frustrated, travels 100 miles back home; swings by
mail box to get mail before going into the driveway and pulls the full set of
plans out from the manufacturer that Rater had requested to do the plan
review several weeks ago!
• Builder receives the home from manufacturer; has it set on the foundation and
begins the finish process
• Forgot to tell the manufacturer that the customer changed the HVAC units to the
non-Energy Star spec’d units to save money so they could buy new furniture and a
hot tub instead; house no longer qualifies for Energy Star, but didn’t tell customer
who still thinks they have an Energy Star home
Builder • As builder finishes the final walk-through with customer, the HERS Rater pulls into
the site after a 150 mile trip to complete the performance testing and certification;
Rater speaks to builder, learns about changes, and heads home without testing
• Moves into home in April; has no complaints
• Gets first electric and gas bills for December and can’t understand why it is double
what was estimated by the utility company for an Energy Star home
• Begins to notice that the house is cold and drafty during the winter months and bills
continue to climb
C t
Customer • Utility company arranges energy audit including infrared scan to determine possible
issues
9
10. 3/10/2009
Lack of coordination between Builders and
Manufacturers
Connection of HERS raters near final project
sites to manufacturers and builders
Lack of education and training of builders, set
crews, subs and manufacturers
Energy Star process not a priority in the
modular production p
p process
Lack of accuracy in predicting when units will
be ready for TBC inspection by rater in plant
and site testing
Customer – Production – Delivery &
Learns Works with Set – Knows
Requirements/ HERS Requiremen
Costs Upfront! Rater/QC ts for Set
Builder – Engineering Builder Finish
Knows – Knows – Must Final
Requirements Requirement Seal and Close
/Costs s/Costs Building
Envelope
Factory Sales –
Knows Estimating HERS Rater
Requirements/ – Knows Blower Door
Costs/Contacts Requirements/ Test / Certify -
HERS Rater Costs Customer
Occupies
10
11. 3/10/2009
A Transition is Occurring…
•Earliercontact between rater
and builder is starting to occur
(but slowly)
•Vigilance on the QC/QA Front
to insure that the standards are
being met (improving but not
fully implemented)
•Recent government actions at
State and Federal levels are
redirecting financial incentives
to residential, commercial and
industrial projects – existing
and new construction
No consistent contact Plants starting to
person in plant designate ES/Green
ES process initiated with specialist
Rater after house on line g g y
Starting to get activity in
sales phase or early
Grade III or failing production phase
fiberglass insulation Insulation work seeing
work great improvements;
Personnel changes after majority are Grade II/III
training in proper More air sealing
techniques strategies recognized
Lack of air sealing and implemented
strategies in place or Still room for
sufficiently completed improvement!
Initially… Today…
11
16. 3/10/2009
Air infiltration at drywall & window molding
Insulation Around Perimeter Band Joist
Common industry practice to
put 3’ – 4’ of batt insulation from
perimeter towards center of unit
16
17. 3/10/2009
Insulation
Cold air
Insulation was installed on the exterior band joist across the ceiling three feet.
This did not stop or reduce the amount of air flow across the ceiling to the
marriage wall.
Similar to site construction…Insulation installation is one
of the least popular tasks often left to the newest hire or
least skilled labor.
17
18. 3/10/2009
Garage Below Second Floor Bonus Room
Air flow at base plate of wall and through
fiberglass wall insulation
Wiring chase ways should be sealed.
Compressed insulation
Electrical panel located on exterior wall. Allows air movement and
moisture movement as well as limits the amount of insulation in the
wall cavity.
18
19. 3/10/2009
Poorly fitting fiberglass batt
insulation; subcontractor re-work
breaches thermal envelope.
(Bump out Photo)
Cold air
moving to
center
marriage
wall from
between
mod 1 & 2
19
20. 3/10/2009
Bump out section where multiple modules
connect. Cold air at center support beam.
This dark area is where the modular first floor bump out was attached to
the first floor rear section. Air is infiltrating at the connection of these
two boxes which indicates a lack of proper sealing between units. (L)
20
21. 3/10/2009
•Fiberglass insulation is
not enough to properly
seal
•Air seal the perimeter
between floors before
siding is installed.
•Seal all gaps on the
marriage wall at
archways and door
openings before
installing trim.
Communications established between HERS rater and
Manufacturer
Manufacturer hands off project coordination for final
testing to Rater and Builder
HERS Rater sets up date for field testing; explains to
builder how it will be done and required conditions
Builder calls 1 week before testing and moves
scheduled performance testing out an additional 3
weeks
HERS Rater arrives on site on new date, but house not
ready for testing and Rater finds deficiencies in site
work that will challenge the ability to pass ES testing
21
23. 3/10/2009
Connection between basement, Unsealed duct chase into
apartment, bonus room, and living space from garage…
attic…
Air handler located in unconditioned
attic…disconnected ductwork
23
24. 3/10/2009
Standard EPA New Home Protocol
◦ Plan Review/Consultation
◦ Thermal Bypass Checklist (In plant Inspection)
(In-plant
◦ Final Performance Testing
Blower Door
Ductblaster
MHRA Protocol
◦ Plant Certification
◦ 3rd Party Q of In-house QC
y QA Q
◦ Energy Star Ready
◦ On Site Sampling Protocol for Builders; 1 in 7 per
HERS Rater Acceptance
24
25. 3/10/2009
Lack of contact between customer/builder and
manufacturer at beginning of sales process
Manufacturers not involved in site aspect of
planning and design
Lack of education/training with all stakeholders
Lack of enthusiasm with sales staffs and builders;
results in a lack of confidence to sell Green and
Energy Star programs
Fear of additional costs by consumers, builders,
manufacturers
Continue to educate and train industry staff and
builders
Breakdown certification process and d l
B kd tifi ti d develop
training that integrates into existing process
Utilize grants and incentives to entice entry into
Green market and philosophy
Constantly reinforce benefits and true cost “savings”
by g g Green (with emphasis on Energy and
y going ( p gy
Quality)
Establish Partnerships to spread message and
opportunities with like minded organizations!
25
26. 3/10/2009
Factory Built Housing Center
Pennsylvania College of Technology
DIF#153, 1 College Ave.
Williamsport, PA 17701
570-327-4768
fterry@pct.edu & larmanda@pct.edu
http://www.pct.edu/wdce/fbhc
26
